101691-9862 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016919862


101691-9862 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101691-9862 1016919862

Cross reference number

ZEXEL 101691-9862 1016919862


Zexel num
Bosch num
Firm num
Name
101691-9862 
101691-9868 
 
  NISSAN-DIESEL
INJECTION-PUMP ASSEMBLY
FE6T *

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8140
Bosch type code   EF8511/9A
Nozzle   105780-0000
Bosch type code   DN12SD12T
Nozzle holder   105780-2080
Bosch type code   EF8511/9
Opening pressure MPa   17.2
Opening pressure kgf/cm2   175
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   6-2-600
Overflow valve   132424-0620
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
Tester oil delivery pressure kPa   157 157 157
Tester oil delivery pressure kgf/cm2   1.6 1.6 1.6
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-4-2-6- 3-5
Pre-stroke mm   3.4 3.35 3.45
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-4
deg.   60 59.5 60.5
Difference between angles 2
Cyl.1-2
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cal 1-3
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-5
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   -
Rack position   14
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   84.8 82.8 86.8
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   9.7+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   9.5 7.7 11.3
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(14)
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   84.8 83.8 85.8
Basic   *
Fixing the lever   *
Boost pressure kPa   25.3 25.3
Boost pressure mmHg   190 190
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.1
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   91.9 88.7 95.1
Fixing the lever   *
Boost pressure kPa   25.3 25.3
Boost pressure mmHg   190 190
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.3
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   96.5 93.3 99.7
Fixing the lever   *
Boost pressure kPa   25.3 25.3
Boost pressure mmHg   190 190
Injection quantity adjustment_06
Adjusting point   D
Rack position   R2(12.3)
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   59.7 58.7 60.7
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_07
Adjusting point   I
Rack position   16.1+-0. 5
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   83.5 83.5 103.5
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   550 550 550
Rack position   R2(12.3)
Boost pressure kPa   4 2.7 5.3
Boost pressure mmHg   30 20 40
Boost compensator adjustment_02
Pump speed r/min   550 550 550
Rack position   R1(14)
Boost pressure kPa   12 12 12
Boost pressure mmHg   90 90 90

Test data Ex:

Governor adjustment

Test data 101691-9862
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=C44 BCL=(1.7)+-0.1mm
----------

Timer adjustment

Test data 101691-9862
(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N3=800r/min C3=(4deg) t1=2--sec. t2=2--sec.
----------
N1=1200++r/min N2=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=2.5--deg C2=4+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

Test data 101691-9862
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=26.5deg+-5deg b=(44deg)+-3deg

Stop lever angle

Test data 101691-9862
N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=40deg+-5deg

0000001501 RACK SENSOR

Test data 101691-9862
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack limit adjustment (1)Fix the rack at the rack limit position Ra. (2)Install the shim (D) to the rod (C) and tighten nut (E). (3)Select a shim (D) so that the distance between the end surface of the pump and the nut (E) is L. (4)Release the rack fixing and mount the joint (B) and fix. (5)At this time, confirm that the shim (D) does not interfere with the joint (B). 2. Rack sensor adjustment (-0420) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set the speed to N1 r/min. (4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR. (6)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
L=33-0.2mm N1=550r/min Ra=R1(14)mm
----------

Timing setting

Test data 101691-9862
(1)Pump vertical direction (2)Position of timer's threaded hole at the No. 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)




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